COURSE OVERVIEW:

The meaning of pumping system optimization refers to the process of analyzing and improving the interaction between pumps, prime movers, control systems, and the piping network to achieve the lowest energy cost per unit of fluid moved. This course focuses on the "system approach" rather than individual component efficiency, recognizing that most industrial pumps are oversized or poorly matched to their actual process requirements. By mastering the physics of head, flow, and power, participants can identify significant energy reduction opportunities that often exceed thirty percent of current consumption.

The scope of this training encompasses the technicalities of pump performance curves, system curves, and the "Best Efficiency Point" (BEP) for various centrifugal and positive displacement technologies. It examines the impact of pump wear, internal clearances, and fluid viscosity on thermodynamic efficiency, providing a comprehensive toolkit for diagnosing mechanical and hydraulic losses. The course provides a deep dive into the selection and implementation of Variable Frequency Drives (VFDs) and the comparative energy analysis of throttling, bypassing, and speed control.

Coverage includes the analysis of "Life Cycle Costing" (LCC) for pumping assets, the implementation of "Intelligent Pumping" systems with integrated sensors, and the reduction of frictional losses through pipe diameter optimization. The course addresses the critical challenge of "Net Positive Suction Head" (NPSH) management and its role in preventing cavitation-induced energy waste and equipment damage. Participants will gain practical expertise in conducting pumping system audits, utilizing ultrasonic flow measurement, and formulating optimization roadmaps that align with ISO 50001 energy management standards.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Define the core components of an industrial pumping system and their energy roles.

2.  Construct and interpret Pump Performance Curves and System Curves accurately.

3.  Identify the "Best Efficiency Point" (BEP) and the energy cost of operating away from it.

4.  Calculate "Specific Energy Consumption" for various pumping applications.

5.  Evaluate the energy impact of "Safety Margins" and pump oversizing in design.

6.  Quantify the energy savings potential of Variable Frequency Drives (VFDs).

7.  Compare the efficiency of throttling valves, bypass loops, and impeller trimming.

8.  Analyze the impact of fluid viscosity and specific gravity on power draw.

9.  Diagnose "Cavitation" and NPSH issues using hydraulic and acoustic data.

10.  Utilize "Parallel and Series" pumping strategies for optimal system flexibility.

11.  Conduct a comprehensive Pumping System Audit using HI and ASME standards.

12.  Formulate a technical business case for high-efficiency pumping retrofits.

TARGET AUDIENCE:

This course is designed for Mechanical Engineers, Plant Maintenance Managers, Energy Auditors, Utility Supervisors, and Process Engineers responsible for fluid handling in industrial facilities.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.